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Related Manuals for Hitachi ZX 38U-5A
Summary of Contents for Hitachi ZX 38U-5A
- Page 1 PART NO. TADC-EN-01 Technical Manual Hydraulic Excavator URL:http://www.hitachi-c-m.com Service Manual consists of the following separate Part No. Technical Manual : Vol. No.TADC-EN Workshop Manual : Vol. No.WADC-EN PRINTED IN JAPAN (K) 2014, 09 Engine Manual : Vol. No.ETADB-EN, EWADB-EN...
- Page 3 FAX: 81-29-831-1162 E-mail: HCM-TIC-GES@hitachi-kenki.com Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual. Manual Composition This manual consists the Technical Manual, the Workshop ...
- Page 4 INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and CAUTION: signal words are used to alert the reader to the potential Indicates potentially hazardous situation which could, if for personal injury of machine damage. not avoided, result in personal injury or death.
- Page 5 SYMBOL AND ABBREVIATION Symbol / Name Explanation Abbreviation Technical manual (Operational principle) Technical manual (Operational Principle). Technical manual (Troubleshooting) Technical manual (Troubleshooting). Technical manual Technical manual. W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly and Assembly). E-ECU Engine Controller Engine controller.
- Page 6 SYMBOL AND ABBREVIATION (Blank) SY-2...
- Page 7 SAFETY Recognize Safety Information These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. SA-688 Understand Signal Words ...
- Page 8 Hitachi Warranty Policy. Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...
- Page 9 SAFETY Prepare For Emergencies Be prepared if a fire starts or if an accident occurs. Keep a first aid kit and fire extinguisher on hand. Thoroughly read and understand the label attached on the fire extinguisher and use it properly. ...
- Page 10 SAFETY Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine ...
- Page 11 SAFETY General Precautions for Cab Always keep inside the cab clean by observing instructions below, to prevent any personal accidents from occurring. Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots.
- Page 12 SAFETY Adjust the Operator’s Seat A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to mis- operation of the machine. The seat should be adjusted whenever the operator for the machine changes.
- Page 13 SAFETY Fasten Your Seat Belt If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. Be sure to remain seated with the seat belt securely fastened whenever operating the machine.
- Page 14 SAFETY Operate Only From Operator’s Seat Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only when seated in the operator’s seat. NEVER start the engine while standing on the tracks or on ground.
- Page 15 SAFETY Precautions for Operations Thoroughly make certain safety at the work site before starting operations. Especially always observe the following points. Be sure to wear close fitting clothing and required safety items, such as a hard hat, when operating the machine. ...
- Page 16 SAFETY Investigate Job Site Beforehand When working at the edge of an excavation or on a road shoulder, the machine could tip over due to collapse of the ground, possibly resulting in serious injury or death. Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
- Page 17 In case the machine is operated in areas where the possibility of falling stones or debris exists, equip genuine Hitachi OPG guard. Contact your nearest Hitachi dealer for installation method of the OPG guard. Depending on the specifications applied to your machine, modification of the machine to meet ROPS standards will be possible.
- Page 18 SAFETY Drive Machine Safely Use a signal person when traveling the machine along road shoulders or in congested areas. Driving the machine in the incorrect direction may result in serious injury or death and/or severe damage to property. ...
- Page 19 SAFETY When the machine descends a slope at high speed, machine weight accelerates descending speed. It may cause collision accident due to misjudging of braking distance or machine turnover due to running on an unexpected obstacle. Always ensure that travel mode display (1) on the monitor , and then reduce the engine speed before descending a slope.
- Page 20 SAFETY Avoid Injury From Rollaway Accidents Death or serious injury may result if you attempt to mount or try to bodily stop a moving machine. Park the machine in compliance with the safe parking procedures described in operator's manual to prevent the machine from running away.
- Page 21 SAFETY Avoid Injury From Back-over and Swing Accidents If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: ...
- Page 22 SAFETY Keep Person Clear From Working Area If a person is present near the operating machine, the person may come in contact with the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. ...
- Page 23 SAFETY Avoid Tipping The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: Be extra careful before operating on a grade. Prepare machine operating area flat. ...
- Page 24 SAFETY Dig With Caution Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. Before digging check the location of cables, gas lines, and water lines. Keep the minimum distance required, by law, from cables, gas lines, and water lines.
- Page 25 SAFETY Precautions For Lightning The machine is vulnerable to lightning strikes. In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to a safe place far away from the machine. ...
- Page 26 SAFETY Protect Against Flying Debris If flying debris such as soil, rock fragments or metal pieces hit eyes or any other part of the body, serious injury may result. Guard against such injuries when working in a job site where possibility of flying pieces of metal or debris exist, or when removing or installing pins using a hammer;...
- Page 27 SAFETY Handle Fluids Safely --- Avoid Fires Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. Do not refuel the machine while smoking or when near open flame or sparks.
- Page 28 SAFETY Transport Safely The danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed. Be sure to observe local regulations when transporting the machine on public roads. Provide an appropriate truck or trailer for transporting the machine.
- Page 29 SAFETY Practice Safe Maintenance Inspection/maintenance work may produce hazardous situations by contacting and/or accessing a part of body to a moving, high pressure, and/or high temperature part of the machine. To avoid serious personal injury or death, follow the instructions described below. ...
- Page 30 SAFETY Disconnect battery ground cable (−) before making adjustments to electrical systems or before welding on the machine. Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
- Page 31 SAFETY Support Machine Properly Never attempt to work on the machine without securing the machine first. Always lower the attachment to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment with stays or blocks strong enough to support the machine and/or attachment weight.
- Page 32 SAFETY Prevent Parts From Flying Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. Do not attempt to remove GREASE FITTINGS or VALVE ASSEMBLIES. ...
- Page 33 SAFETY Prevent Burns Hot spraying fluids: After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. ...
- Page 34 SAFETY Replace Rubber Hoses Periodically Rubber hoses that contain flammable fluids such as hydraulic oil or fuel under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by visual inspection alone.
- Page 35 SAFETY Prevent Fires Check for Oil Leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires, possibly resulting in personal injury or death. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil- cooler, and loose oil-cooler flange bolts, for oil leaks.
- Page 36 SAFETY Clean up Flammables: Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.
- Page 37 SAFETY Evacuating in Case of Fire If fire breaks out during machine operation, evacuate the machine in the following way: Stop the engine by turning the key switch to the OFF position. Use a fire extinguisher if there is time. ...
- Page 38 Keep the units away from open flames and fire. Do not bore a hole, do not cut by torch. Avoid giving shocks by hitting or rolling the unit. Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer. SA-32...
- Page 39 Keep bystanders out of the work site during operation. Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. SA-33...
- Page 40 SAFETY Prevent Battery Explosions Battery gas can explode. Keep sparks, lighted matches, and flame away from the top of battery. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. ...
- Page 41 Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and battery. When draining fluid, use a leakproof container with a capacity larger than the drained fluid volume to receive it.
- Page 42 SAFETY Never Ride Attachment Never allow anyone to ride attachments or the load. This is an extremely dangerous practice. Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices. Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.
- Page 43 SAFETY Precaution for Communication Terminal Equipment A mobile communication terminal which transmits radio wave is located in the monitor cover at front right of the operator's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment.
- Page 44 (When required to remove or install the communication terminal, consult your nearest Hitachi dealer.) Do not pinch or forcibly pull cables, cords or connectors. Failure to do so may cause short circuit or broke circuit that may result in damage and/or fire to the base machine or to the communication terminal.
- Page 45 The right is reserved to make changes at any time Group 2 Monitor without notice. Group 3 Troubleshooting A Group 4 Troubleshooting B Group 5 Air Conditioner COPYRIGHT(C)2014 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved...
- Page 46 WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank Group 5 Hydraulic Circuit Pressure Release Procedure Group 6 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Front Attachment...
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Page 47: Table Of Contents
SECTION 1 GENERAL CONTENTS Group 1 Specifications Std. Specification..............T1-1-1 Working Ranges ..............T1-1-2 Group 2 Component Layout Main Component ..............T1-2-1 Electrical System (Overview) .......... T1-2-2 Electrical System (Relays) ..........T1-2-3 Electrical System (Relays) (Cab Spec. Machine) ..T1-2-4 Electrical System (Monitor, Switches) ...... - Page 48 (Blank) ADCT-1-2...
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Page 49: Group 1 Specifications
SECTION 1 GENERAL Group 1 Specifications Std. Specification ZX38U-5A MADG-12-001 Model ZX38U-5A Specification Canopy Type of Front-End Boom Swing Type, 1.72 m (5 ft 8 in) Arm Attachment Bucket Capacity (Heaped) 0.10 (0.13) Operating Weight kg (lb) 3790 (8360) 3960 (8730) Base Machine Weight kg (lb) 2930 (6460) -
Page 50: Working Ranges
SECTION 1 GENERAL Group 1 Specifications Working Ranges ZX38U-5A K (Left) K (Right) MADC-12-004 ZX38U-5A Category Canopy Item 1.32 m Arm 1.72 m Arm 1.32 m Arm 1.72 m Arm Maximum Digging Reach mm (ft·in) 5210 (17' 1") 5520 (18' 1") 5210 (17' 1") 5520 (18' 1") Maximum Digging Depth... -
Page 51: Group 2 Component Layout
SECTION 1 GENERAL Group 2 Component Layout Main Component TADB-01-02-008 Coolant Reservoir Lower Roller Blade Cylinder Fuel Tank Radiator/Oil Cooler Pilot Filter Boom Cylinder Hydraulic Oil Tank Air Cleaner Upper Roller Bucket Cylinder Battery Water Separator Filter Control Valve Arm Cylinder Blade Pilot Valve Engine Track Adjuster... -
Page 52: Electrical System (Overview)
SECTION 1 GENERAL Group 2 Component Layout Electrical System (Overview) TADB-01-02-009 Electrical System (Monitor, 2-Spool Solenoid Valve Electrical System (Battery Components Related with Switches) (Refer to T1-2-5.) Components Related with Room) (Refer to T1-2-6.) Engine (Refer to T1-2-7.) Electrical System (Relays) Control Valve (Refer to T1- Torque Control Solenoid (Refer to T1-2-3, 4.) -
Page 53: Electrical System (Relays)
SECTION 1 GENERAL Group 2 Component Layout Electrical System (Relays) TAEA-01-02-003 View A 13 12 TAEA-01-02-004 TAEA-01-02-005 Travel Mode Selector Relay Light Relay 12. Main Relay Pilot Shut-Off Relay Horn Relay 13. Rack Actuator Relay Travel Alarm Relay (Optional) Travel Mode Selector Relay Fuse Box Unit R2 Cut Relay (Optional) - Page 54 SECTION 1 GENERAL Group 2 Component Layout Electrical System (Relays) (Cab Spec. Machine) TAEA-01-02-003 Machine with Heater Machine with Air Conditioner 1 3 4 TAEA-01-02-018 TAEA-01-02-010 Blower Motor Relay (Mid) Blower Motor Relay (Low) Displacement Angle Compressor Relay Blower Motor Relay (High) Selection Relay T1-2-4...
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Page 55: Electrical System (Monitor, Switches)
SECTION 1 GENERAL Group 2 Component Layout Electrical System (Monitor, Switches) 10 11 12 13 14 MADB-01-002 TAEA-01-02-015EN TAEA-01-02-014 Horn Switch *Wiper Switch 17- Auto Shut-Down Indicator 25- Travel Mode Indicator Engine Control Dial Work Light Switch (Optional) 26- Work Light Indicator Travel Mode Switch 10- Overheat Indicator 18- Fuel Gauge... -
Page 56: Electrical System (Battery Room)
SECTION 1 GENERAL Group 2 Component Layout Electrical System (Battery Room) TADB-01-02-005 TADB-01-02-010 Slow Blow Fuse Glow Plug Relay Starter relay 1 Travel Alarm (Optional) E-ECU T1-2-6... -
Page 57: Engine
SECTION 1 GENERAL Group 2 Component Layout Engine TADB-01-02-006 TADB-01-02-007 View A TADB-01-02-011 Alternator Engine Speed Sensor Glow Plug Fuel Feeding Pump Starter Engine Oil Pressure Switch Overheat Switch Rack Actuator Coolant Temperature Sensor CSD Valve T1-2-7... -
Page 58: Swing Device
SECTION 1 GENERAL Group 2 Component Layout Swing Device Travel Device T1M7-01-02-006 T1M7-01-02-004 Control Valve 11 10 TADB-01-02-004 Relief Valve Main Relief Valve (Main Pump Overload Relief Valve (Boom Overload Relief Valve (Arm Counterbalance Valve Lower) Roll-In) Travel Mode Selector Valve Boom Anti-Drift Valve Overload Relief Valve (Boom Main Relief Valve (Main Pump... -
Page 59: 2-Spool Solenoid Valve
SECTION 1 GENERAL Group 2 Component Layout 2-Spool Solenoid Valve Torque Control Solenoid Valve (Only machine with the air conditioner (optional) attached) T1M7-01-02-008 TAEA-01-02-009 Machine Front Pilot Relief Valve Torque Control Solenoid Pilot Shut-Off Solenoid Valve Valve (Only machine with Travel Mode Selector the air conditioner (optional) Solenoid Valve... - Page 60 SECTION 1 GENERAL Group 2 Component Layout (Blank) T1-2-10...